Installation Procedure
- Clean the clutch hub and the input shaft from any debris and contaminates with a lint-free towel.
- Use a clean flat brush (1) to apply very light coating of multi-purpose grease to input shaft until the metal is only shiny . No visible clumps of grease are permissible regardless of size. Smear away from the transmission in direction of the shown arrow.
- Clean the entire lead surface of the input shaft with a NEW, lint-free towel (1).
- Raise the transmission with the transmission jack and position the transmission to the engine.
- Install the lower transmission bolts (1) and tighten to 60 N.m (44 lb ft).
- Install the lower transmission bolts (2) and tighten to 40 N.m (32 lb ft).
- Install the lower transmission bolt (3) and nut (4) and tighten to 40 N.m (32 lb ft).
- Remove the transmission jack.
- Install the left transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side .
- Install the left transmission mount (4). Refer to Transmission Mount Replacement - Left Side .
- Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
- Install the rear transmission mount (3). Refer to Transmission Rear Mount Replacement .
- Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement .
- Install the right front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement .
- Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV,LUW) .
- Remove the engine support fixture. Refer to Engine Support Fixture .
- Install the upper transmission to engine bolts (1) and tighten to 60 N.m (44 lb ft).
- Connect the speedometer driven gear electrical connector (1).
- Connect the electrical connector (1) to the backup lamp switch (2).
- Connect the wiring harness clamp to the transmission.
- Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow.
- Lock the clutch actuator cylinder front pipe retaining clip (1).
- Connect the shift lever and selector lever cable ends (1) to the transmission shift lever and selector lever.
- Install the shift lever and the selector lever cable (3) to the shift lever and the selector lever cable bracket.
- Adjust the shift lever and selector lever cables. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment .
- Connect the brake booster vacuum hose (1 )to the engine intake manifold.
- Fill the transmission with fluid. Refer to Transmission Fluid Drain and Fill .
- Install the radiator surge tank. Refer to Radiator Surge Tank Replacement .
- Install the battery and battery tray. Refer to Battery Tray Replacement .
- Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding .
- Road test the vehicle.
Use care when cleaning the clutch hub. The clutch hub may have sharp edges and can cause personal injury if contact is made. Wear protective gloves to avoid personal injury.
Applying too much or the wrong type of grease on the transmission input shaft may cause damage, clutch slippage or failure. Always apply the correct type of grease. Never apply more grease than is necessary to coat the transmission input shaft with a very thin film of grease.
Ensure that no grease remains on the lead surface of the transmission input shaft. Clean the lead surface of the transmission input shaft prior to the assembly of the transmission to the engine. Failure to maintain a clean surface may cause clutch slippage or failure.
Refer to Fastener Caution .
The clutch actuator cylinder front pipe must engage noticeably.